Panel manufacturing machine and method

ABSTRACT

A panel manufacturing machine and method adapted to produce panels of building blocks; the machine and method involving the formation of a horizontal course of blocks in end-to-end relation to each other with mortared head joints between ends of the blocks and with bed mortar on top of the blocks, which course is transferred as a unit to be assembled with other courses of blocks to produce a panel. Further, the machine and method can progressively sense a modular measurement longitudinally of said course to control the overall length of each course when assembled and mortared together.

United States Patent [191 Wright et al,

[ Jan. 29, 1974 PANEL MANUFACTNG MACHINE AND METHQD [75] lnventors: Lawrence W. Wright, Scottsdale;

Leon H. Tolleson; Daniel P. Abrahamson, both of Phoenix; Paul M. Thomas, Paradise Valley; Eugene E. Cirile, Phoenix, all of Ariz.

[73] Assignee: The Thomas 1970 Trust, Phoenix,

Ariz.

[22] Filed: Apr. 30, 1971 [21] Appl. No.: 138,949

Related US. Application Data [63] Continuation-in-part of Ser. No. 132,788, April 9,

1971, abandoned.

[52] US. Cl 264/261, 52/747, 52/749, l56/64, 156/71, 264/275, 425/472 [51] int. Cl E0441 2/02 [58] Field of Search..... 52/747, 749, 297, 298, 304; 150/71; 156/182; 264/261, 275; 156/64; 425/472 [56] References Cited UNITED STATES PATENTS 3,325,960 6/1967 James 52/747 3,438,171 4/1969 Demarest 52/749 3,503,174 3/1970 Nichols 3,585,092 6/1971 Storer 156/182 Primary Examiner-Edward G. Whitby Attorney, Agent, or Firm-Fitch, Even, Tabin & Luedeka [5 7] ABSTRACT A panel manufacturing machine and method adapted to produce panels of building blocks; the machine and method involving the formation of a horizontal course of blocks in end-to-end relation to each other with mortared head joints between ends of the blocks and with bed mortar on top of the blocks, which course is transferred as a unit to be assembled with other courses of blocks to produce a panel. Further, the machine and method can progressively sense a modular measurement longitudinally of said course to control the overall length of each course when assembled and mortared together.

8 Claims, 50 Drawing Figures PATENTEU JAHZS L974 sum 01 or 32 00 g r INVENTORSI LAWRENCE W. WRIGHT LEON H. TOLLESON DANIEL P. ABRAHAMSON PAUL M. THOMAS EUGENE E. CRILE ATTORNEY SHEET 020F 32 PATENTH] JAN 2 91974 SHEEI USUF 32 PATENTEI] JAN 2 91974 SHEH 08 0F 32 wwE PATENIED JAN 2 9 I974 sum 07 or '32 PATENTED 3.789.101

SHEET 09oF 32 PATENTEDJAHZQ m SHEET 1 1 OF 32 vee PAIENIEUM 3.789.101

sum 12 or 52 FIG I? PATENIED JAN 2 9 I974 SHEET 150F132 PATENIEBJAHZSIEIM sum 16 0F 32 mom PAIENIED 3,789,101

sum 17 0F 32 

1. In a method for the manufacture of a prefabricated wall panel wherein a plurality of blocks are laid in end-to-end relation on a substantially horizontal supporting surface with their adjacent facing end surfaces mortared one to another to form vertically disposed head joints and define a horizontal course, and such course of blocks is subsequently combined with additional courses to form said wall panel, the improvement comprising the steps of aligning a plurality of said blocks in end-to-end relationship, advancing said blocks in the direction of their longitudinal dimension a modular distance equal to the nominal length of a block plus the nominal thickness of a mortar head joint, positioning a block within said modular distance, spacing said block apart from a previously positioned block to define a head joint space between adjacent facing end surfaces of said blocks, mortaring said facing adjacent end surfaces of said blocks to join said blocks in a course, clamping the resulting course of mortared blocks in alignment, and combining said clamped course with other courses so formed.
 2. The method of claim 1 wherein a layer of bed mortar is applied to the upper surfaces of said blocks prior to combining said clamped course with other courses.
 3. The method of making a mortared course of a given length from building blocks which may have variations in length from a nominal dimension, comprising the steps of aligning a plurality of blocks in a horizontally disposed course, moving the blocks in alignment in a direction parallel to the longitudinal axis of said course, successively placing mortar between adjacent surfaces of said blocks to form vertically disposed head joints, prior to each successive placement of mortar between adjacent surfaces of said blocks to form a head joint positioning the trailing surface of the unmortared trailing block rearwardly along the line of movement of said course a distance from the trailing surface of the leading mortared block equal to the nominal dimension of the trailing block plus the thickness of a nominal head joint.
 4. The method of claim 3 wherein the partial course of mortared blocks after head joints are made is conveyed in increments equal to the nominal dimension of the trailing unmortared block plus the thickness of a nominal head joint.
 5. The method of claim 3 wherein the mortar in said head joint is compacted to render it substantially incompressible.
 6. The method of claim 4 wherein the clamped course is vibrated as a unit as that course is properly being spaced from its adjacent course.
 7. The method of making a wall panel from a plurality of mortared courses of building blocks each having head joints and a layer of bed mortar on the upper surface thereof, and wherein the height of the blocks in each course may vary from a nominal dimension, comprising the steps of clamping a course of mortared blocks in alignment, moving the clamped course into vertical alignment with another course, and moving the courses together until the distance between the lower surface of the blocks in one course and the lower surface of the blocks in the adjacent course are spaced apart a distance equal to the nominal height of a block in the course plus the nominal thickness of a bed joint.
 8. A method for establishing substantially precise overall length of an elongated course of blocks formed by a plurality of such blocks disposed in end-to-end relation to each other with mortar head joints therebetween; the method comprising: first preparing an elongated makeup table having first and second ends; conveying blocks one at a time in end-to-end relation to each other and on to said first end of said makeup table; placing head joint mortar between adjacent ends of a pair of said blocks each time an additional block is conveyed onto said makeup table; progressively moving a plurality of said blocks and respective head joint mortar longitudinally along said makeup table in a direction from said first end toward said second end thereof and measuring the overall length of a plurality of said blocks and respective head joints each time an additional block and head joint is added to said plurality of blocks; and compensating the dimension of each successive head joint as each additional block is added to thereby attain a precise overall length of a course of mortared-together blocks. 